Pneumatic spring provided with a level measuring device

ABSTRACT

The invention relates to a pneumatic spring ( 2 ) essentially comprising two terminal elements ( 4, 6 ), a pressure-tight roll bellows which is arranged therebetween and made of a flexible elastomeric electroconductive material ( 14 ), a strengthening carrier ( 16 ) formed by two cord-fibre plies ( 16   a,    16   b ) which are made of threads ( 18 ), crossed at an angle (γ) and vulcanised inside said bellows. In order to determine the height (h) of the spring, in a preferred embodiment, said two cord-carcass plies ( 16   a,    16   b ) are provided with a certain number of highly conductive threads ( 18   a ) which are arranged at the beginning and the end of each ply in a parallel direction to each other, thereby forming two conductive strips ( 24   a,    24   b ). Said conductive strips ( 24   a,    24   b ) are disposed oppositely to each other and electrically connected at the end of the roll bellows ( 8 ) in such a way that a conductive loop ( 24 ) is formed and each strip is used as a branch for an alternating current measuring bridge ( 28 ). In such manner, only the filaments ( 20 ) of each thread ( 18 ) or certain filaments ( 20   a ) of the threads ( 18 ) can be electrically conductive. In addition to determining the height (h) of the spring in a motor vehicle, the inventive device can be also used for determining air pressure in the bellows of the pneumatic spring ( 2 ), the temperature (T) of the bellow walls and other measurable quantities.

STATE OF THE ART

The invention relates to an air spring having a level measuring unit such as known, for example, from the publications DE 100 17 562 C1, DE 40 35 784 A1 and DE 44 13 559 A1. The features of the preamble are taken from DE 100 25 631 A1.

In each of the above examples, the air spring comprises essentially two variably mutually spaced end members, namely, a cover and a roll-off piston and a flexible member clamped pressure tight therebetween, especially, a rolling-lobe flexible member.

In publication DE 100 25 631 A1, a method is described wherein the height of the spring is determined by means of the high frequency hollow space resonance. The flexible member must have good conductivity so that the flexible member performs as an electromagnetic hollow space resonator. This can, for example, be achieved in that the reinforcements, which are introduced into the flexible member, are electrically conductive.

This publication emphasizes details of the measuring electronics. Details as to the configuration of the electrically conductive reinforcements are not disclosed.

According to DE 100 17 562 C1, the measurement of height takes place with the aide of two coils one of which is mounted axially secure within the air spring interior space and the other one of the coils is mounted between the cover and the roll-off piston so as to be changeable in length. A level dependent measurement signal results because of the change of the height position of the air spring as well as because of the compression operation. The length-changeable coil can be an integral component of the flexible member, that is, of the wall. This coil is either pressed onto the surface of the flexible member facing inwardly or is glued or is worked directly between the layers.

An application of the coil of this kind on or in the wall of the flexible member requires an additional work step in the production of the flexible member or in the production of the air spring. Problems can develop with the flexibility of the wall of the flexible member (harshness effect) because the coil is not mounted in the plane of the fabric ply or plies.

The flexible members of the air springs, described in publications DE 40 35 784 A1 and DE 44 13 559 A1, likewise show measurement fibers worked into the wall.

It is, however, the case that according to DE 40 35 784 A1, electrical conductors are worked into the wall of the flexible member in the form of a coil or diagonally. Here, the conductor paths are configured as a coil to be changeable in length with the coil being applied to a latex monofil. The incorporation of latex monofil fibers, which are provided with electrically conducting coils, into the wall of the flexible member is likewise associated with additional work complexity in the manufacture.

According to DE 44 13 559 A1, the electrically conductive measuring fibers, which are integrated into the wall of the flexible member, are characterized by running parallel to the fiber direction of a fabric ply and in the longitudinal direction of the flexible member from one flexible member end to the other. Because of the position and the arrangement of these conductor paths, their inductivity changes with the spring height because of the spring operation.

The fibers, which are to be introduced into the wall of the flexible member, comprise, for example, copper strands which must be introduced into the wall of the flexible member in addition to the textile fabric plies or in lieu of individual fibers of the fabric plies. If the copper fibers are not arranged in the plane of the textile reinforcement, then there results overall a stiffening of the wall of the flexible member and the consequences are a pronounced harshness effect. If the copper fibers are in the plane of the textile reinforcement, then there results an inhomogeneous expansion of the wall of the flexible member during loading because of the different expansion characteristics of the copper strands and textile cords whereby the service life of the flexible member is affected.

TASK OF THE INVENTION

The task of the invention comprises providing a wall of the flexible member, which is provided with electrically conductive measuring fibers for an air spring which does not exhibit the disadvantages listed from the state of the art.

The electrically conductive flexible member wall should function especially as measuring means to determine the spring height.

SOLUTION AND ADVANTAGES

The essential essence of the invention lies in a specific configuration of the reinforcement built up from the filaments, namely, in a metalization of the individual filaments.

For this reason, the electrically conductive filaments are an integral component of the textile fabric ply (plies) of the air spring flexible member. The electrically conductive filaments are made of the same basic material as the other, that is, nonconducting filaments and are only coated with a conductive surface. For this reason, an identical, that is, homogeneous expansion behavior results over the entire wall of the flexible member. And because the electrically conductive filaments are not arranged in a separate plane, there results also no stiffening of the wall of the flexible member and therefore also no additional harshness effect. The electrically conductive coating is already undertaken during the manufacture of the filaments. A separate work step during manufacture of the flexible member wall is therefore not present.

The wall of the flexible member, which is provided with electrically conductive filaments in accordance with the invention, defines the basis for the solution of the diverse measuring tasks.

With the solution set forth in the patent claims, not only (as required) a measuring method is provided for determining the spring height.

In addition, the air pressure, which is present in the air spring flexible member, and the temperature of the wall of the flexible member can be determined. Furthermore, a measurement of the fiber expansion is possible. Likewise, occurring or already occurred damage because of stone impact, wear, et cetera, can be detected early. Furthermore, it is possible to transmit electrical energy along the spring flexible member and to heat the air spring flexible member. The structures according to the invention of conductive fibers to build measuring resistances, measuring capacitors and thermal elements are integral components of the fabric in the air spring. In this way, separate measuring quantity transformers for the solution of the particular measuring task are unnecessary.

The integrated sensors are based on similar conductor structures, which, depending upon the circuitry, solve different individual tasks: thus, the conductor strips for expansion measurement can also be used for detecting damage on the outer wall of the flexible member. The same applies for the capacitors for measuring flexible member pressure. The capacitors can also be used for detecting damage caused by wear.

In two applications, the hardware for evaluating the measuring signals is very similar: the alternating current bridge for the evaluation of the capacitances between the fabric plies is also suitable for evaluating the inductivity of the conductor loop for the height measurement.

In detail:

Measurement of the Temperature in the Wall of the Flexible Member

Up to now, discrete temperature sensors (for example, thermoelements) have to be vulcanized in in order to be able to determine the temperature in the wall of the flexible member. Alternatively, the temperature can be contactlessly measured from the outside with the aid of pyrometric methods. All methods described are complex and therefore limited to individual applications (for example, in the development of air springs).

Measurement of the Fiber Expansion

The fiber expansion in the fabric of an air spring can not, up to now, be measured directly.

Early Detection of Damage

Wear-caused damage to air spring flexible members (which do not yet lead to air losses) can up to now only be determined via a visual check. Because this is very complex, the air springs are, as a rule, utilized so long until they get noticed because of air loss.

Transmission of Electrical Energy Along the Spring Flexible Member

The air spring flexible member comprises nonconductors. Up to now, cables are necessary in order to supply electronic components in the roll-off piston with electrical energy.

Electrical Heating of Air Spring Flexible Members

At the present time no heatable air springs are known.

The following advantages are presented individually:

a) Measurement of the Flexible Member Pressure

The otherwise required connection point for a pressure sensor is not necessary because of the integrated measuring quantity converter.

b) Measurement of the Temperature in the Wall of the Flexible Member

The integrated resistance paths and the thermal elements, which are formed from conductive fibers, replace external components for measuring temperature. Furthermore, all series air springs can be equipped with a temperature measurement with the conductor structures according to the invention in the fabric. The operational reliability of the spring increases because of the monitoring of the temperature in the rolling lobe which is especially subjected to mechanical load.

c) Measurement of the Fiber Expansion

By connecting the light conductive fibers to form expansion measuring strips, it is now possible to directly measure the expansion of the fibers, which function as reinforcement, and are located within the flexible member wall.

d) Early Detection of Damage

The early detection of damage to an air spring increases the reliability of the vehicle. Furthermore, the detection of wear-caused damage is important in the service life experiments in the context of the development of air springs.

e) Transmission of Electrical Energy Along the Spring Flexible Member

Electrical components, which are disposed in the piston of the air spring system or on the axle, can be supplied with energy without external cables. The electrical energy can be fed via a plug on the cover plate and separate cables are unnecessary because the conductors are an integral part of the air spring flexible member.

f) Electrical Heating of Air Spring Flexible Members

Air spring flexible members with elastomers on the basis of chloroprene are not suitable for applications at temperatures below −25° C. because the elastomer reaches the glass transition point. For lower temperatures, natural rubber is therefore used. With an electrical heating of the spring flexible member with the aid of the conductive fibers in the fabric, the temperature at the outer flexible member wall can be so controlled that it always lies above the glass transition point of chloroprene. In this way, the area of application of this elastomer material expands.

DRAWINGS

In the following, the invention will be described with reference to several embodiments.

FIG. 1 shows the schematic representation of an air spring in longitudinal section;

FIG. 2 a shows the schematic representation of a crossed arrangement of cord fabric plies in an air spring rolling-lobe flexible member (not shown here in the entirety);

FIG. 2 b shows section A-A of FIG. 2 a;

FIG. 3 shows a reinforcement filament which is coated with a thin metal layer;

FIG. 4 shows a reinforcement fiber comprising filaments with some of the filaments being metallized;

FIG. 5 shows the section from a fabric ply wherein a specific number of conventional fibers are replaced with conductive fibers;

FIG. 6 a shows a perspective view of the external fabric ply of an air spring flexible member;

FIG. 6 b shows, in plan, two conductor loops which are electrically connected to each other at the lower end of the spring and are arranged in the fabric;

FIGS. 7 a/b show schematics of the areas covered by the conductive strips, namely, FIG. 7 a in the compressed state and FIG. 7 b in the rebound state;

FIG. 8 shows a block circuit diagram with an alternating current bridge circuit of the conductor loops (shown in FIGS. 6 a/b and FIGS. 7 a/b) for determining the height;

FIG. 9 shows a crossover location of two fabric plies;

FIG. 10 shows an alternating current bridge circuit for determining the capacity of two crossover locations;

FIGS. 11 a/b show schematics of an expansion measuring arrangement, that is, FIG. 11 a shows layer 1 and FIG. 11 b shows layer 2;

FIG. 12 shows a block circuit diagram with a wheatstone bridge for temperature determination; and,

FIG. 13 shows a block circuit diagram with a wheatstone bridge for evaluating the expansion measurement according to FIGS. 11 a/b.

DESCRIPTION

The schematic of FIG. 1 shows the essential details of an air spring 2: two end members (4, 6), which are spaced variably from each other, that is, a cover 4 and a roll-off piston 6. The air spring also includes a rolling-lobe flexible member 8 clamped pressure tight between the cover 4 and the roll-off piston 6.

With the aid of a level control system (not shown), the height (level) h, which is given in each case between cover 4 and roll-off piston 6, can be controlled by changing the air pressure p present in the air spring volume 10. The rolling lobe 12 of the flexible member 8 rolls on the outer wall of the roll-off piston 6. The rolling-lobe flexible member 8 comprises an elastomeric material 14 and is reinforced by a reinforcement 16.

The reinforcement 16 of the air spring 2, as a rule, comprises two crossed-over cord fabric plies (16 a, 16 b) (FIG. 2 a) which are each vulcanized into the elastomeric material 14 of the flexible member 8 (FIG. 2 b).

The basic idea of the invention is to intersperse the fabric plies (16 a, 16 b) of the textile reinforcement 16 with fibers 18 which have filaments 20 coated with a thin metal layer 22 (0.6 μm to 0.7 μm) in order to rake them electrically conductive (FIG. 3). To achieve moderate conductivity, only individual metallized filaments 20 a are worked into the fiber 18. The conductivity of the fibers 18 increases with the number of metallized filaments 20 a (FIG. 4). Also, entire fibers 18 can be metallized (metallized fiber 18 a, FIG. 5). The filaments 20 according to the invent: on and the fibers 18 are made, for example, of polyamide PA 6.6 which is coated with nickel, copper and/or silver (metal layer 22).

In the manufacture of the fabric plies (16 a, 16 b), a specific number of conventional fibers 18 is replaced by conductive fibers 18 a (FIG. 5). The number and density of the electrically conductive fibers 18 a and their electrical conductivity is determined in accordance with the task to be solved.

a) Measuring the Spring Height

In a fabric ply 16 a or 16 b or in both fabric plies (16 a, 16 b), a number of highly conductive fibers 18 a is connected in parallel to form a conductor strip (24 a and/or 24 b). Two conductor strips 24 from the same fabric ply 16 a or 16 b, which lie on the periphery opposite each other, are connected electrically to each other (bridge 26) at the lower end of the air flexible member and form a conductive loop 24 whose conductivity L is essentially dependent upon the developed area A (FIGS. 7 a/b) which increases substantially linearly with the instantaneous spring height. For the evaluation, the conductor loop 24 is placed as a changing element in an alternating-current bridge circuit 28 and is supplied with a high frequency current. With a second conductor loop 24, which is arranged on the periphery offset by 90°, the complete bridge can be assembled (FIG. 8) whose sensitivity can be varied via a frequency f of the supply current.

b) Measurement of Flexible Member Pressure

In each of the two fabric plies (16 a, 16 b), several highly conductive fibers are connected in parallel to form conductive loops (24 a, 24 b) which function as an equi-potential area for a capacitive arrangement. The conductor strips (24 a, 24 b) of the two fabric plies (16 a, 16 b) are normally insulated with respect to each other by the elastomer 14. Where the strips (24 a, 24 b) of the two fabric plies (16 a, 16 b) cross, an electric capacitance C results therebetween whose value is dependent upon the crossover area A_(C) of the two strips (24 a, 24 b) (FIG. 9) and from their distance d to each other. The crossover area A_(C) as well as the distance d between the fabric plies (16 a, 16 b) are dependent upon the fabric angle γ which becomes less with increasing pressure p, in the spring 2. C=ε ₀·ε_(r) ·A _(C)(γ)/d(γ).

While the crossover area A_(C) becomes less because of the fabric angle γ, which becomes ever smaller with increasing pressure p, the thickness of the wall of the flexible member, and therefore the distance d between the fiber layers (16 a, 16 b), does not change uniformly with the pressure p.

In order to determine the pressure p, the capacitances C at each two crossover locations 30 above the rolling lobe 12 (FIG. 1) are evaluated with the aid of an alternating-current bridge circuit 28 (FIG. 10). The sensitivity of the bridge circuit can be changed via the work frequency f.

c) Measurement of the Temperature in the Wall of the Flexible Member (Resistance Measuring Bridge)

The basis of this method are the conductor structures for measuring the fiber expansion (FIGS. 11 a/b). The difference comprises that the fibers 18 are made conductive with the aid of different metals which exhibit different temperature coefficients. The temperature dependent and expansion dependent resistance paths are connected as a wheatstone measuring bridge 32 (FIG. 12) and in such a manner that the expansion of the fibers 18 in the two conductor strips mutually compensate while the different temperature coefficients lead to the condition that the resistance changes Δ_(R) unbalance the bridge 32 because of the temperature T and generate a corresponding output signal U_(R).

d) Measurement of the Fiber Expansion

The expansion or stretching of a fiber 18 in the fabric 16 is dependent upon the position of the particular measuring point on the fiber 18. The expansion is minimal at the connection to the piston 6 and increases outwardly over the rolling lobe 12. The fiber expansion is a maximum at the outer wall of the flexible member above the rolling lobe 12.

At this location, individual conductive fibers 18 a of defined length are collected together in one of the two fabric plies 16 a or 16 b so that they form an expansion measuring strip (FIGS. 11 a/b). The expansion-dependent resistance change of the strip is evaluated with the aid of a wheatstone bridge circuit 32 (FIG. 13).

e) Early Detection of Damage

One Ply

For the detection of damage of the spring flexible member 8, several conductive strips are formed from several fibers 18 in the outer fabric ply 16 a or 16 b and their total resistance R is monitored (FIGS. 11 a/b). Individual filaments 20 or fibers 18 a in the conductive strips are damaged or cut through because of damage such as stone impact or abrasion whereby the total resistance R of the strips increases.

Two Plies

Wear-caused damage often begins with the separation of the elastomer 14 from a fabric ply 16 a or 16 b. In order to detect this damage, conductive strips are formed in both fabric plies (16 a, 16 b) (FIG. 9). The capacitance C between these strips is monitored. The capacitance changes very greatly when the elastomer 14 separates from a fabric ply 16 a or 16 b because the resulting dielectric number ε_(r) thereby reduces drastically.

f) Transmission of Electrical Energy along the Spring Flexible Member

For the transmission of electrical energy to electronic components, which are located in the piston 6 of an air spring 2, several highly conductive fibers 18 a in a fabric ply 16 a or 16 b are combined to the required number of conductors (FIG. 6 a, without bridge).

g) Electrical Heating of the Air Spring Flexible Members

A moderate number of conductive fibers 18 a of the two fabric plies (16 a, 16 b) are connected together to form heater resistors and are supplied with electrical energy (FIG. 6 a) in order to transfer heat to the wall of the flexible member. The heating of the flexible member can be limited to the rolling lobe 12, which is especially mechanically loaded, in order to reduce the requirement as to electrical heating power.

A control of the heating power ensures that the temperature T of the outer wall of the flexible member 8 does not drop below a critical value. For the control, a temperature sensor is required on the wall of the flexible member in principle. The heating fibers in the fabric are slightly warmer than the wall of the flexible member on the outside because of the heat conductance through the elastomer 14 so that also the temperature T of the wall of the flexible member can be applied as a control quantity.

REFERENCE CHARACTER LIST

-   2 air spring -   4, 6 end members -   4 cover -   6 roll-off piston, piston -   8 rolling-lobe flexible member, air spring flexible member -   h height (level) of the air spring -   10 air spring volume -   p air pressure -   12 rolling lobe -   14 elastomeric material, elastomer -   16 reinforcement, fabric -   16 a, 16 b (cord) fabric ply (plies) of the reinforcement, fiber     layer(s) -   18 fiber, fibers, filament(s) -   18 a metallized fiber -   20 filament(s) -   20 a metallized filament -   22 metal layer, electrically conductive coating -   24 conductor loop -   24 a conductor strips, number of highly conductive fibers 18 a (in     fabric ply 16 a) -   24 b the same in fabric ply 16 b -   A area developed by conductor loop 24 -   26 bridge -   L inductivity of the conductor loop 24 -   28 alternating-current bridge circuit -   f frequency, work frequency -   C electrical capacitance between the fabric plies 16 a and 16 b in     the region of the crossover of the two conductor strips -   A_(C) crossover area -   d distance of the fabric layers from each other -   γ fabric angle -   ε₀ electrical field constant (=8.85416·10⁻¹² F·m⁻¹) -   ε_(r) dielectric number -   30 crossover location -   T temperature -   U_(T) thermal stress -   32 wheatstone measuring bridge -   ΔR resistance change -   U_(R) output signal -   R (total) resistance 

1-22. (canceled)
 23. An air spring comprising: a cover; a roll-off piston disposed in spaced relationship to said cover; a rolling-lobe flexible member made of elastomeric material and clamped pressure tight between said cover and said roll-off piston; said flexible member containing a reinforcement vulcanized into said elastomeric material; said reinforcement including two cord fabric plies arranged in said flexible member so as to crossover at an angle (γ); each of said cord fabric plies including a plurality of fibers; each of said fibers including a plurality of filaments; and, at least a number of the filaments of at least selected ones of said fibers being electrically conductive.
 24. The air spring of claim 23, wherein all of the individual filaments of said selected ones of said fibers are electrically conductive.
 25. The air spring of claim 23, wherein the electrically conductive filaments have a carrier and an electrically conductive coating covering said carrier.
 26. The air spring of claim 25, wherein the electrically conductive coating is a metal layer which is tightly joined to said carrier.
 27. The air spring of claim 26, wherein the metallized filaments are coated with nickel, copper and/or silver.
 28. The air spring of claim 23, wherein said selected ones of said fibers are totally metallized (metallized fibers).
 29. The air spring of claim 23, wherein a predetermined number of conventional fibers are replaced by conductive fibers with the ratio of conductive fibers and nonconductive fibers and the conductive value of the conductive fibers is dependent on the task to be solved.
 30. The air spring of claim 23, wherein: in one fabric ply or in both fabric plies, a number of highly conductive fibers are connected in parallel at the beginning and at the end of the particular fabric ply and in each case, form conductive strips; two of these conductive strips of a fabric ply, which lie opposite each other at the periphery, are electrically connected to each other at the end of the air spring flexible member and thereby form, in each case, a conductor loop.
 31. The air spring of claim 30, wherein the conductor loops of the two fabric plies form respective elements in corresponding branches of an alternating-current bridge circuit.
 32. The air spring of claim 31, wherein the frequency (f) of the alternating-current voltage, which is applied to the alternating-current bridge circuit, is variable.
 33. The air spring of claim 23, wherein several highly conductive fibers of each of said fabric plies form a conductive strip by being connected in parallel; the strips of the two fabric plies are insulated with respect to each other by the elastomer and form an electric capacitance (C) at a crossover location of said fabric plies whereat a crossover area (A_(C)) is defined; the value of the electric capacitance being dependent upon said crossover area (A_(C)) of the two strips and on their distance (d) to each other; and, said crossover area (A_(C)), in turn, being a function of the fabric angle (γ).
 34. The air spring of claim 33, wherein the capacitance (C) of each two crossover locations, which are disposed above the rolling lobe, are respective capacitive impedances of an alternating-current bridge circuit.
 35. The air spring of claim 34, wherein the sensitivity of the bridge circuit can be changed by the selection of the work frequency (f).
 36. The air spring of claim 23, wherein said selected ones of said fibers are made conductive with the aid of different metals which have different temperature coefficients.
 37. The air spring of claim 36, wherein conductive fibers of each of said fabric plies form a conductive strip; the temperature dependent and expansion dependent resistance paths form elements of a wheatstone measuring bridge in such a manner that the expansion of the fibers mutually compensate in the two conductor strips; whereas, the different temperature coefficients have, as a consequence, a temperature-dependent unbalance with a corresponding output signal.
 38. The air spring of claim 23, wherein in one fabric ply or in both fabric plies, individual fibers of defined length are combined to define an expansion measuring strip and form an element of a wheatstone bridge circuit.
 39. The air spring of claim 23, wherein several conductive fibers in one fabric ply or in both fabric plies form several conductive strips for the purpose of monitoring the total resistance (R) thereof.
 40. The air spring of claim 39, wherein several conductive fibers form conductive strips in both fabric plies; and, the strips form a capacitance (C) at their crossover locations and the magnitude thereof changes in a measurable manner when there is a separation of a fabric ply.
 41. The air spring of claim 23, wherein several highly conductive fibers are combined in a fabric ply for the purpose of transmitting electrical energy or electrical signals to at least one electronic component.
 42. The air spring of claim 23, wherein moderately conductive fibers of both fabric plies are connected to each other to form heating resistors.
 43. The air spring of claim 42, wherein the heatable fibers are limited to the rolling lobe which is especially mechanically loaded.
 44. The air spring of claim 43, wherein a control of the rolling lobe heating resistances while considering a critical limit value by means of a thermal sensor; and, the control quantity being given by the temperature (T) of the heating fibers. 